Ice mold for a clear ice making assembly

ABSTRACT

An ice making assembly includes an ice mold including two or more separable portions that collectively define one or more mold cavities. Each of the mold portions define a plurality of recessed passages that at least partially surround the mold cavity and are configured to receive evaporator conduit of a sealed refrigeration to cool the ice mold and facilitate formation of an ice billet.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage Entry of and claims thebenefit of priority under 35 U.S.C. § 371 to PCT Application Serial No.PCT/CN2020/128636 filed Nov. 13, 2020 and entitled ICE MOLD FOR A CLEARICE MAKING ASSEMBLY, which is hereby incorporated by reference in itsentirety.

FIELD OF THE INVENTION

The present subject matter relates generally to ice making appliances,and more particularly to ice molds for an ice making appliance thatproduces large, clear pieces of ice.

BACKGROUND OF THE INVENTION

In domestic and commercial applications, ice is often formed as solidcubes, such as crescent cubes or generally rectangular blocks.Specifically, certain ice makers include a freezing mold that defines aplurality of cavities that can be filled with liquid water that freezeswithin the plurality of cavities to form solid ice cubes. Typical solidcubes or blocks may be relatively small in order to accommodate a largenumber of uses, such as temporary cold storage and rapid cooling ofliquids in a wide range of sizes.

Notably, ice formed using conventional ice making appliances oftensuffers from impurities and gases that are trapped within ice cubesduring formation. These impurities and gases may impart undesirableflavors into a beverage being cooled (i.e., a beverage in which the icecube is placed) as the ice cube melts. In addition, these impurities andgases may cause an ice cube to melt unevenly or faster (e.g., byincreasing the exposed surface area of the ice cube). In recent years,ice making appliances have been developed for forming relatively largeice billets in a manner that avoids trapping impurities and gases withinthe billet. In addition to forming ice that is more evenly-distributedor slower melting, these clear ice cubes (e.g., free of any visibleimpurities or dull finish) may provide a unique or upscale impressionfor the user.

Certain ice making appliances for forming large, clear ice billetsutilize an inverted or upside-down mold and a spray nozzle that sprayswater upwards into the mold cavity. In this manner, impurities fall backinto a water basin while pure water slowly forms ice within the mold. Inthis regard, water in the cavities begins to freeze and solidify firstfrom the sides and top surfaces, and slowly fills the remaining volumeof the mold cavity. Notably, however, conventional ice molds used insuch a system have limited cooling capacity, resulting in long iceformation times to achieve a clear ice billet. In addition, temperaturedistribution within such molds is very non-uniform, resulting intemperature gradients within the ice billet that cause cracking duringformation or release.

Accordingly, further improvements in the field of ice making would bedesirable. More specifically, a clear ice making mold assembly that canreduce ice formation times while reducing the likelihood of crackingwould be particularly beneficial.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

In one exemplary embodiment, an ice making assembly is providedincluding an ice mold defining a mold cavity, wherein the ice molddefines a plurality of recessed passages that at least partiallysurround the mold cavity, a sealed refrigeration system including acondenser and an evaporator in serial flow communication with eachother, the evaporator being positioned within the plurality of recessedpassages to cool the ice mold, and a pump assembly for urging anice-building spray into the ice mold to form an ice billet.

In another exemplary embodiment, a mold assembly for an ice makingassembly is provided. The mold assembly includes an ice mold including afirst portion and a second portion that are separable and define a moldcavity, wherein the ice mold defines a plurality of recessed passagesthat at least partially surround the mold cavity and are configured forreceiving evaporator conduit.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures.

FIG. 1 provides a side plan view of an ice making appliance according toexemplary embodiments of the present disclosure.

FIG. 2 provides a schematic view of an ice making assembly according toexemplary embodiments of the present disclosure.

FIG. 3 provides a simplified perspective view of an ice making assemblyaccording to exemplary embodiments of the present disclosure.

FIG. 4 provides a cross-sectional, schematic view of the exemplary icemaking assembly of FIG. 3.

FIG. 5 provides a cross-sectional, schematic view of a portion of theexemplary ice making assembly of FIG. 3 during an ice forming operation.

FIG. 6 provides a perspective view of an ice mold and an evaporatorassembly according to an exemplary embodiment of the present subjectmatter.

FIG. 7 provides a bottom perspective view of the exemplary ice mold andevaporator assembly of FIG. 6 according to an exemplary embodiment ofthe present subject matter.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the present invention.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the invention, notlimitation of the invention. In fact, it will be apparent to thoseskilled in the art that various modifications and variations can be madein the present invention without departing from the scope or spirit ofthe invention. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

As used herein, the terms “first,” “second,” and “third” may be usedinterchangeably to distinguish one component from another and are notintended to signify location or importance of the individual components.The terms “upstream” and “downstream” refer to the relative flowdirection with respect to fluid flow in a fluid pathway. For example,“upstream” refers to the flow direction from which the fluid flows, and“downstream” refers to the flow direction to which the fluid flows. Theterms “includes” and “including” are intended to be inclusive in amanner similar to the term “comprising.” Similarly, the term “or” isgenerally intended to be inclusive (i.e., “A or B” is intended to mean“A or B or both”).

Approximating language, as used herein throughout the specification andclaims, is applied to modify any quantitative representation that couldpermissibly vary without resulting in a change in the basic function towhich it is related. Accordingly, a value modified by a term or terms,such as “about,” “approximately,” and “substantially,” are not to belimited to the precise value specified. In at least some instances, theapproximating language may correspond to the precision of an instrumentfor measuring the value. For example, the approximating language mayrefer to being within a 10 percent margin.

Turning now to the figures, FIG. 1 provides a side plan view of an icemaking appliance 100, including an ice making assembly 102. FIG. 2provides a schematic view of ice making assembly 102. FIG. 3 provides asimplified perspective view of ice making assembly 102. Generally, icemaking appliance 100 includes a cabinet 104 (e.g., insulated housing)and defines a mutually orthogonal vertical direction V, lateraldirection, and transverse direction. The lateral direction andtransverse direction may be generally understood to be horizontaldirections H.

As shown, cabinet 104 defines one or more chilled chambers, such as afreezer chamber 106. In certain embodiments, such as those illustratedby FIG. 1, ice making appliance 100 is understood to be formed as, or aspart of, a stand-alone freezer appliance. It is recognized, however,that additional or alternative embodiments may be provided within thecontext of other refrigeration appliances. For instance, the benefits ofthe present disclosure may apply to any type or style of a refrigeratorappliance that includes a freezer chamber (e.g., a top mountrefrigerator appliance, a bottom mount refrigerator appliance, aside-by-side style refrigerator appliance, etc.). Consequently, thedescription set forth herein is for illustrative purposes only and isnot intended to be limiting in any aspect to any particular chamberconfiguration.

Ice making appliance 100 generally includes an ice making assembly 102on or within freezer chamber 106. In some embodiments, ice makingappliance 100 includes a door 105 that is rotatably attached to cabinet104 (e.g., at a top portion thereof). As would be understood, door 105may selectively cover an opening defined by cabinet 104. For instance,door 105 may rotate on cabinet 104 between an open position (notpictured) permitting access to freezer chamber 106 and a closed position(FIG. 2) restricting access to freezer chamber 106.

A user interface panel 108 is provided for controlling the mode ofoperation. For example, user interface panel 108 may include a pluralityof user inputs (not labeled), such as a touchscreen or button interface,for selecting a desired mode of operation. Operation of ice makingappliance 100 can be regulated by a controller 110 that is operativelycoupled to user interface panel 108 or various other components, as willbe described below. User interface panel 108 provides selections foruser manipulation of the operation of ice making appliance 100 such as(e.g., selections regarding chamber temperature, ice making speed, orother various options). In response to user manipulation of userinterface panel 108, or one or more sensor signals, controller 110 mayoperate various components of the ice making appliance 100 or ice makingassembly 102.

Controller 110 may include a memory (e.g., non-transitive memory) andone or more microprocessors, CPUs or the like, such as general orspecial purpose microprocessors operable to execute programminginstructions or micro-control code associated with operation of icemaking appliance 100. The memory may represent random access memory suchas DRAM, or read only memory such as ROM or FLASH. In one embodiment,the processor executes programming instructions stored in memory. Thememory may be a separate component from the processor or may be includedonboard within the processor. Alternatively, controller 110 may beconstructed without using a microprocessor (e.g., using a combination ofdiscrete analog or digital logic circuitry; such as switches,amplifiers, integrators, comparators, flip-flops, AND gates, and thelike; to perform control functionality instead of relying uponsoftware).

Controller 110 may be positioned in a variety of locations throughoutice making appliance 100. In optional embodiments, controller 110 islocated within the user interface panel 108. In other embodiments, thecontroller 110 may be positioned at any suitable location within icemaking appliance 100, such as for example within cabinet 104.Input/output (“I/O”) signals may be routed between controller 110 andvarious operational components of ice making appliance 100. For example,user interface panel 108 may be in communication with controller 110 viaone or more signal lines or shared communication busses.

As illustrated, controller 110 may be in communication with the variouscomponents of ice making assembly 102 and may control operation of thevarious components. For example, various valves, switches, etc. may beactuatable based on commands from the controller 110. As discussed, userinterface panel 108 may additionally be in communication with thecontroller 110. Thus, the various operations may occur based on userinput or automatically through controller 110 instruction.

Generally, as shown in FIGS. 3 and 4, ice making appliance 100 includesa sealed refrigeration system 112 for executing a vapor compressioncycle for cooling water within ice making appliance 100 (e.g., withinfreezer chamber 106). Sealed refrigeration system 112 includes acompressor 114, a condenser 116, an expansion device 118, and anevaporator 120 connected in fluid series and charged with a refrigerant.As will be understood by those skilled in the art, sealed refrigerationsystem 112 may include additional components (e.g., one or moredirectional flow valves or an additional evaporator, compressor,expansion device, or condenser). Moreover, at least one component (e.g.,evaporator 120) is provided in thermal communication (e.g., conductivethermal communication) with an ice mold or mold assembly 130 (FIG. 3) tocool mold assembly 130, such as during ice making operations.Optionally, evaporator 120 is mounted within freezer chamber 106.

Within sealed refrigeration system 112, gaseous refrigerant flows intocompressor 114, which operates to increase the pressure of therefrigerant. This compression of the refrigerant raises its temperature,which is lowered by passing the gaseous refrigerant through condenser116. Within condenser 116, heat exchange with ambient air takes place soas to cool the refrigerant and cause the refrigerant to condense to aliquid state.

Expansion device 118 (e.g., a mechanical valve, capillary tube,electronic expansion valve, or other restriction device) receives liquidrefrigerant from condenser 116. From expansion device 118, the liquidrefrigerant enters evaporator 120. Upon exiting expansion device 118 andentering evaporator 120, the liquid refrigerant drops in pressure andvaporizes. Due to the pressure drop and phase change of the refrigerant,evaporator 120 is cool relative to freezer chamber 106. As such, cooledwater and ice or air is produced and refrigerates ice making appliance100 or freezer chamber 106. Thus, evaporator 120 is a heat exchangerwhich transfers heat from water or air in thermal communication withevaporator 120 to refrigerant flowing through evaporator 120.

Optionally, as described in more detail below, one or more directionalvalves may be provided (e.g., between compressor 114 and condenser 116)to selectively redirect refrigerant through a bypass line connecting thedirectional valve or valves to a point in the fluid circuit downstreamfrom the expansion device 118 and upstream from the evaporator 120. Inother words, the one or more directional valves may permit refrigerantto selectively bypass the condenser 116 and expansion device 120.

In additional or alternative embodiments, ice making appliance 100further includes a supply valve 122 for regulating a flow of liquidwater to ice making assembly 102. For example, supply valve 122 may beselectively adjustable between an open configuration and a closedconfiguration. In the open configuration, supply valve 122 permits aflow of liquid water to ice making assembly 102 (e.g., to a pumpassembly 132 or a water basin 134 of ice making assembly 102).Conversely, in the closed configuration, supply valve 122 hinders theflow of liquid water to ice making assembly 102. However, it should beappreciated that certain exemplary embodiments require no supply valveat all.

In certain embodiments, ice making appliance 100 also includes adiscrete chamber cooling system 124 (e.g., separate from sealedrefrigeration system 112) to generally draw heat from within freezerchamber 106. For example, discrete chamber cooling system 124 mayinclude a corresponding sealed refrigeration circuit (e.g., including aunique compressor, condenser, evaporator, and expansion device) or airhandler (e.g., axial fan, centrifugal fan, etc.) configured to motivatea flow of chilled air within freezer chamber 106. According to anexemplary embodiment, a second evaporator may be tied into the chambercooling system 124 or sealed cooling system 124.

Turning now to FIGS. 3 and 4, FIG. 4 provides a cross-sectional,schematic view of ice making assembly 102. As shown, ice making assembly102 includes a mold assembly 130 that defines a mold cavity 136 withinwhich an ice billet 138 may be formed. Optionally, a plurality of moldcavities 136 may be defined by mold assembly 130 and spaced apart fromeach other (e.g., perpendicular to the vertical direction V). One ormore portions of sealed refrigeration system 112 may be in thermalcommunication with mold assembly 130. In particular, evaporator 120 maybe placed on or in contact (e.g., conductive contact) with a portion ofmold assembly 130. During use, evaporator 120 may selectively draw heatfrom mold cavity 136, as will be further described below. Moreover, apump assembly 132 positioned below mold assembly 130 may selectivelydirect the flow of water into mold cavity 136. Generally, pump assembly132 includes a circulation pump 140 and at least one nozzle 142 directed(e.g., vertically) toward mold cavity 136. In embodiments whereinmultiple discrete mold cavities 136 are defined by mold assembly 130,pump assembly 132 may include a plurality of nozzles 142 or fluid pumpsvertically aligned with the plurality mold cavities 136. For instance,each mold cavity 136 may be vertically aligned with a discrete nozzle142.

In some embodiments, a water basin 134 is positioned below the ice mold(e.g., directly beneath mold cavity 136 along the vertical direction V).Water basin 134 includes a solid nonpermeable body and may define avertical opening 145 and interior volume 146 in fluid communication withmold cavity 136. When assembled, fluids, such as excess water fallingfrom mold cavity 136, may pass into interior volume 146 of water basin134 through vertical opening 145. In certain embodiments, one or moreportions of pump assembly 132 are positioned within water basin 134(e.g., within interior volume 146). As an example, circulation pump 140may be mounted within water basin 134 in fluid communication withinterior volume 146. Thus, circulation pump 140 may selectively drawwater from interior volume 146 (e.g., to be dispensed by spray nozzle142). Nozzle 142 may extend (e.g., vertically) from circulation pump 140through interior volume 146.

In optional embodiments, a guide ramp 148 is positioned between moldassembly 130 and water basin 134 along the vertical direction V. Forexample, guide ramp 148 may include a ramp surface that extends at anegative angle (e.g., relative to a horizontal direction) from alocation beneath mold cavity 136 to another location spaced apart fromwater basin 134 (e.g., horizontally). In some such embodiments, guideramp 148 extends to or terminates above an ice bin 150. Additionally oralternatively, guide ramp 148 may define a perforated portion 152 thatis, for example, vertically aligned between mold cavity 136 and nozzle142 or between mold cavity 136 and interior volume 146. One or moreapertures are generally defined through guide ramp 148 at perforatedportion 152. Fluids, such as water, may thus generally pass throughperforated portion 152 of guide ramp 148 (e.g., along the verticaldirection V between mold cavity 136 and interior volume 146). It shouldbe appreciated that according to alternative embodiments, any suitableapparatus for separating falling liquid water from falling ice may beused.

As shown, ice bin 150 generally defines a storage volume 154 and may bepositioned below mold assembly 130 and mold cavity 136. Ice billets 138formed within mold cavity 136 may be expelled from mold assembly 130 andsubsequently stored within storage volume 154 of ice bin 150 (e.g.,within freezer chamber 106). In some such embodiments, ice bin 150 ispositioned within freezer chamber 106 and horizontally spaced apart fromwater basin 134, pump assembly 132, or mold assembly 130. Guide ramp 148may span the horizontal distance between mold assembly 130 and ice bin150. As ice billets 138 descend or fall from mold cavity 136, the icebillets 138 may thus be motivated (e.g., by gravity) toward ice bin 150.

Turning now generally to FIGS. 4 and 5, exemplary ice forming operationsof ice making assembly 102 will be described. As shown, mold assembly130 is formed from discrete conductive ice mold 160 and insulationjacket 162. Generally, insulation jacket 162 extends downward from(e.g., directly from) conductive ice mold 160. For instance, insulationjacket 162 may be fixed to conductive ice mold 160 through one or moresuitable adhesives or attachment fasteners (e.g., bolts, latches, matedprongs-channels, etc.) positioned or formed between conductive ice mold160 and insulation jacket 162.

Together, conductive ice mold 160 and insulation jacket 162 may definemold cavity 136. For instance, conductive ice mold 160 may define anupper portion 136A of mold cavity 136 while insulation jacket 162defines a lower portion 136B of mold cavity 136. Upper portion 136A ofmold cavity 136 may extend between a nonpermeable top end 164 and anopen bottom end 166. Additionally or alternatively, upper portion 136Aof mold cavity 136 may be curved (e.g., hemispherical) in open fluidcommunication with lower portion 136B of mold cavity 136. Lower portion136B of mold cavity 136 may be a vertically open passage that is aligned(e.g., in the vertical direction V) with upper portion 136A of moldcavity 136. Thus, mold cavity 136 may extend along the verticaldirection between a mold opening 168 at a bottom portion or bottomsurface 170 of insulation jacket 162 to top end 164 within conductiveice mold 160. In some such embodiments, mold cavity 136 defines aconstant diameter or horizontal width from lower portion 136B to upperportion 136A. When assembled, fluids, such as water may pass to upperportion 136A of mold cavity 136 through lower portion 136B of moldcavity 136 (e.g., after flowing through the bottom opening defined byinsulation jacket 162).

Conductive ice mold 160 and insulation jacket 162 are formed, at leastin part, from two different materials. Conductive ice mold 160 isgenerally formed from a thermally conductive material (e.g., metal, suchas copper, aluminum, or stainless steel, including alloys thereof) whileinsulation jacket 162 is generally formed from a thermally insulatingmaterial (e.g., insulating polymer, such as a synthetic siliconeconfigured for use within subfreezing temperatures without significantdeterioration). According to alternative embodiments, insulation jacket162 may be formed using polyethylene terephthalate (PET) plastic or anyother suitable material. In some embodiments, conductive ice mold 160 isformed from material having a greater amount of water surface adhesionthan the material from which insulation jacket 162 is formed. Waterfreezing within mold cavity 136 may be prevented from extendinghorizontally along bottom surface 170 of insulation jacket 162.

Advantageously, an ice billet within mold cavity 136 may be preventedfrom mushrooming beyond the bounds of mold cavity 136. Moreover, ifmultiple mold cavities 136 are defined within mold assembly 130, icemaking assembly 102 may advantageously prevent a connecting layer of icefrom being formed along the bottom surface 170 of insulation jacket 162between the separate mold cavities 136 (and ice billets therein).Further advantageously, the present embodiments may ensure an even heatdistribution across an ice billet within mold cavity 136. Cracking ofthe ice billet or formation of a concave dimple at the bottom of the icebillet may thus be prevented.

In some embodiments, the unique materials of conductive ice mold 160 andinsulation jacket 162 each extend to the surfaces defining upper portion136A and lower portion 136B of mold cavity 136. In particular, amaterial having a relatively high water adhesion may define the boundsof upper portion 136A of mold cavity 136 while a material having arelatively low water adhesion defines the bounds of lower portion 136Bof mold cavity 136. For instance, the surface of insulation jacket 162defining the bounds of lower portion 136B of mold cavity 136 may beformed from an insulating polymer (e.g., silicone). The surface ofconductive mold cavity 136 defining the bounds of upper portion 136A ofmold cavity 136 may be formed from a thermally conductive metal (e.g.,aluminum or copper). In some such embodiments, the thermally conductivemetal of conductive ice mold 160 may extend along (e.g., the entiretyof) of upper portion 136A.

Although an exemplary mold assembly 130 is described above, it should beappreciated that variations and modifications may be made to moldassembly 130 while remaining within the scope of the present subjectmatter. For example, the size, number, position, and geometry of moldcavities 136 may vary. In addition, according to alternativeembodiments, an insulation film may extend along and define the boundsof upper portion 136A of mold cavity 136, e.g., may extend along aninner surface of conductive ice mold 160 at upper portion 136A of moldcavity 136. Indeed, aspects of the present subject matter may bemodified and implemented in a different ice making apparatus or processwhile remaining within the scope of the present subject matter.

In some embodiments, one or more sensors are mounted on or within icemold 160 or in other locations within ice making appliance 100. As anexample, a temperature sensor 180 may be mounted adjacent to ice mold160. Temperature sensor 180 may be electrically coupled to controller110 and configured to detect the temperature at various locations withinice mold 160. Temperature sensor 180 may be formed as any suitabletemperature detecting device, such as a thermocouple, thermistor, etc.Although temperature sensor 180 is illustrated as being mounted to icemold 160, it should be appreciated that according to alternativeembodiments, temperature sensor may be positioned at any other suitablelocation for providing data indicative of the temperature of the icemold 160. For example, temperature sensor 180 may alternatively bemounted to a coil of evaporator 120 or at any other suitable locationwithin ice making appliance 100.

As shown, controller 110 may be in communication (e.g., electricalcommunication) with one or more portions of ice making assembly 102. Insome embodiments, controller 110 is in communication with one or morefluid pumps (e.g., circulation pump 140), compressor 114, flowregulating valves, etc. Controller 110 may be configured to initiatediscrete ice making operations and ice release operations. For instance,controller 110 may alternate the fluid source spray to mold cavity 136and a release or ice harvest process, which will be described in moredetail below.

During ice making operations, controller 110 may initiate or direct pumpassembly 132 to motivate an ice-building spray (e.g., as indicated atarrows 184) through nozzle 142 and into mold cavity 136 (e.g., throughmold opening 168). Controller 110 may further direct sealedrefrigeration system 112 (e.g., at compressor 114) (FIG. 3) to motivaterefrigerant through evaporator 120 and draw heat from within mold cavity136. As the water from the ice-building spray 184 strikes mold assembly130 within mold cavity 136, a portion of the water may freeze inprogressive layers from top end 164 to bottom end 166. Excess water(e.g., water within mold cavity 136 that does not freeze upon contactwith mold assembly 130 or the frozen volume herein) and impuritieswithin the ice-building spray 184 may fall from mold cavity 136 and, forexample, to water basin 134.

Once ice billets 138 are formed within mold cavity 136, an ice releaseor harvest process may be performed in accordance with embodiments ofthe present subject matter. Specifically, referring again to FIG. 3,sealed system 112 may further include a bypass conduit 190 that isfluidly coupled to refrigeration loop or sealed system 112 for routing aportion of the flow of refrigerant around condenser 116. In this manner,by selectively regulating the amount of relatively hot refrigerant flowthat exits compressor 114 and bypasses condenser 116, the temperature ofthe flow of refrigerant passing into evaporator 120 may be preciselyregulated.

Specifically, according to the illustrated embodiment, bypass conduit190 extends from a first junction 192 to a second junction 194 withinsealed system 112. First junction 192 is located between compressor 114and condenser 116, e.g., downstream of compressor 114 and upstream ofcondenser 116. By contrast, second junction 194 is located betweencondenser 116 and evaporator 120, e.g., downstream of condenser 116 andupstream of evaporator 120. Moreover, according to the illustratedembodiment, second junction 194 is also located downstream of expansiondevice 118, although second junction 194 could alternatively bepositioned upstream of expansion device 118. When plumbed in thismanner, bypass conduit 190 provides a pathway through which a portion ofthe flow of refrigerant may pass directly from compressor 114 to alocation immediately upstream of evaporator 120 to increase thetemperature of evaporator 120.

Notably, if substantially all of the flow of refrigerant were divertedfrom compressor 114 through bypass conduit 190 when ice mold 160 isstill very cold (e.g., below 10° F. or 20° F.), the thermal shockexperienced by ice billets 138 due to the sudden increase in evaporatortemperature might cause ice billets 138 to crack. Therefore, controller110 may implement methods for slowly regulating or precisely controllingthe evaporator temperature to achieve the desired mold temperatureprofile and harvest release time to prevent the ice billets 138 fromcracking.

In this regard, for example, bypass conduit 190 may be fluidly coupledto sealed system 112 using a flow regulating device 196. Specifically,flow regulating device 196 may be used to couple bypass conduit 190 tosealed system 112 at first junction 192. In general, flow regulatingdevice 196 may be any device suitable for regulating a flow rate ofrefrigerant through bypass conduit 190. For example, according to anexemplary embodiment of the present subject matter, flow regulatingdevice 196 is an electronic expansion device which may selectivelydivert a portion of the flow of refrigerant exiting compressor 114 intobypass conduit 190. According to still another embodiment, flowregulating device 196 may be a servomotor-controlled valve forregulating the flow of refrigerant through bypass conduit 190. Accordingto still other embodiments, flow regulating device 196 may be athree-way valve mounted at first junction 192 or a solenoid-controlledvalve operably coupled along bypass conduit 190.

According to exemplary embodiments of the present subject matter,controller 110 may initiate an ice release or harvest process todischarge ice billets 138 from mold cavities 136. Specifically, forexample, controller 110 may first halt or prevent the ice-building spray184 by de-energizing circulation pump 140. Next, controller 110 mayregulate the operation of sealed system 112 to slowly increase atemperature of evaporator 120 and ice mold 160. Specifically, byincreasing the temperature of evaporator 120, the mold temperature ofice mold 160 is also increased, thereby facilitating partial melting orrelease of ice billets 138 from mold cavities.

According to exemplary embodiments, controller 110 may be operablycoupled to flow regulating device 196 for regulating a flow rate of theflow of refrigerant through bypass conduit 190. Specifically, accordingto an exemplary embodiment, controller 110 may be configured forobtaining a mold temperature of the mold body using temperature sensor180. Although the term “mold temperature” is used herein, it should beappreciated that temperature sensor 180 may measure any suitabletemperature within the ice making appliance 100 that is indicative ofmold temperature and may be used to facilitate improved harvest of icebillets 138.

Controller 110 may further regulate the flow regulating device 196 tocontrol the flow of refrigerant based in part on the measured moldtemperature. For example, according to an exemplary embodiment, flowregulating device 196 may be regulated such that a rate of change of themold temperature does not exceed a predetermined threshold rate. Forexample, this predetermined threshold rate may be any suitable rate oftemperature change beyond which thermal expansion of ice billets 138 maylead to cracking. For example, according to an exemplary embodiment, thepredetermined threshold rate may be approximately 1° F. per minute,about 2° F. per minute, about 3° F. per minute, or higher. According toexemplary embodiments, the predetermined threshold rate may be less than10° F. per minute, less than 5° F. permanent, less than 2° F. perminute, or lower. According to alternative embodiments, any othersuitable threshold rate may be used. In this manner, flow regulatingdevice 196 may regulate the rate of temperature change of ice billets138, thereby preventing cracking due to thermal expansion.

In general, the sealed system 112 and methods of operation describedherein are intended to regulate a temperature change of ice billets 138to prevent cracking due to thermal expansion. However, although specificcontrol algorithms and system configurations are described, it should beappreciated that according to alternative embodiments variations andmodifications may be made to such systems and methods while remainingwithin the scope of the present subject matter. For example, the exactplumbing of bypass conduit 190 may vary, the type or position of flowregulating device 196 may change, and different control methods may beused while remaining within scope of the present subject matter. Inaddition, depending on the size and shape of ice billets 138, thepredetermined threshold rate and predetermined temperature threshold maybe adjusted to prevent that particular set of ice billets 138 fromcracking, or to otherwise facilitate an improved harvest procedure.

Referring now specifically to FIGS. 6 and 7, an exemplary ice mold 200and evaporator assembly 202 that may be used with ice making appliance100 will be described according to exemplary embodiments of the presentsubject matter. Specifically, for example, ice mold 200 may be used asmold assembly 130 and evaporator assembly 202 may be used as evaporator120 of sealed cooling system 112. Although ice mold 200 and evaporatorassembly 202 are described herein with respect to ice making appliance100, it should be appreciated that ice mold 200 and evaporator assembly202 may be used in any other suitable ice making application orappliance.

As illustrated, ice mold 200 defines one or more mold cavities 210within which ice billets 138 may be formed. Specifically, according tothe illustrated embodiment, ice mold 200 includes two identical moldcavities 210 that are generally gem-shaped. In this regard, for example,mold cavities 210 may have an octagonal cross-section when viewed in ahorizontal plane. It should be appreciated that the number, size, andshape of mold cavities 210 are illustrated and described herein only forthe purpose of explaining aspects of the present subject matter. Assuch, variations and modifications may be made to mold cavities 210while remaining within scope the present subject matter.

In general, ice mold 200 may be formed from any suitable material and inany suitable manner that provides sufficient thermal conductivity totransfer heat to evaporator assembly 202 to facilitate the ice makingprocess. According to an exemplary embodiment, ice mold 200 is formedfrom aluminum, an aluminum alloy, etc. According to still otherembodiments, ice mold 200 may be formed from any other suitablematerial, such as copper, any other metal, or any other suitably rigidand thermally conductive material.

In addition, ice mold 200 may generally be formed from two or moreseparable pieces. These pieces may be joined during the ice makingprocess and separated to simplify ice harvesting. For example, asillustrated, ice mold 200 is formed from a first portion 212 and asecond portion 214. Moreover, first portion 212 and second portion 214are illustrated as being mirror images of each other, e.g., having thesame dimensions, geometry, and a mirrored configuration. As a result,ice mold 200 may define a seam 216 that passes directly through a centerof ice mold 200 to define first portion 212 and second portion 214.Notably, it may be desirable that seam 216 passes through or around eachof the plurality of mold cavities 210 to facilitate easy removal of icebillets 138 after formation. In this regard, ice making assembly 100 mayinclude features or structures for facilitating the simple separation offirst portion 212 and second portion 214 of ice mold 200 on completionof the ice formation process. It should be appreciated that theseparation process may be implemented in conjunction with a harvestingprocess, e.g., using sealed cooling system 112 and flow regulatingdevice 196 to warm ice mold 200 and release ice billets 138.

Although ice mold 200 is illustrated as being formed from first portion212 and second portion 214 to define two mold cavities 210, it should beappreciated that any suitable number of mold portions and mold cavities210 may be used according to alternative embodiments. For example, firstportion 212 and second portion 214 may be elongated such that more thantwo mold cavities 210 are defined along a straight line. According stillother embodiments, additional mold portions may be incorporated todefine any suitable array of mold cavities 210 while maintaining theability to separate the mold portions after formation of ice billets138.

In addition, first portion 212 and second portion 214 are generallyillustrated as being rectangular, e.g., having substantially flat sides220. However, according to alternative embodiments, ice mold 200 mayhave any other suitable geometry or configuration and may include anyother suitable features for improving structural rigidity, thermalconductivity, and/or the ice formation process in general. For example,according to aspects of the present subject matter, each of firstportion 212 and second portion 214 may include features for improvingthe thermal coupling between evaporator assembly 202 and ice mold 200,e.g., to improve the thermal efficiency and thermal distribution of icemaking assembly 100.

Specifically, referring still to FIGS. 6 and 7, ice mold 200 maygenerally define a plurality of recessed passages 230 that extendthrough first portion 212 and second portion 214 to at least partiallysurround mold cavities 210. Moreover, recessed passages 230 maygenerally be sized and configured for receiving evaporator conduit 232of evaporator assembly 202. In this manner, the thermal coupling betweenevaporator assembly 202 and ice mold 200 may be improved such that thecooling capacity and temperature distribution of ice making assembly 100is improved and the resulting ice billets 138 may be formed quickly andefficiently with minimal chance of cracking due to thermal gradientswithin ice mold 200 and ice billets 138. According to exemplaryembodiments, evaporator conduit 232 may be copper tubing. However, itshould be appreciated that any other suitable conduit having highthermal conductivity and structural rigidity may be used.

Specifically, evaporator conduit 232 may be positioned at leastpartially within recessed passages 230 to cool ice mold 200 andfacilitate the ice formation process. According to exemplaryembodiments, evaporator conduit 232 may be positioned in recessedpassages 230 that are defined in any or every surface of ice mold 200that is not defining a portion of mold cavities 210. In this regard,continuing the example from above where ice mold 200 is rectangular andhas six sides 220, recessed passages 230 may be defined (and evaporatorconduit 232 may be placed) in at least four of the six sides 220 offirst portion 212 and second portion 214.

Moreover, it should be appreciated that recessed passages 230 andevaporator conduit 232 may be wrapped or positioned within ice mold 200in any suitable manner or geometry. For example, according to theillustrated embodiment, recessed passages 230 and evaporator conduit 232are serpentine to increase the thermal contact area. According to stillother embodiments, recessed passages 230 and evaporator conduit 232 maybe curvilinear, arcuate, undulating, zigzag, or any other suitableshape. Moreover, evaporator conduit 232 may be routed through the sides220 of ice mold 200 in a sequential manner, such that each side 220receives substantially equivalent cooling capacity of evaporatorassembly 202.

Moreover, the width and depth of recessed passages 230 may be sized forreceipt of evaporator conduit 232 to provide improved thermalcommunication with ice mold 200. In this regard, for example, recessedpassages 230 may define an average depth 240 (e.g., as measured from asurface of side 220 to the deepest portion of recessed passages 230)that is greater than or equal to a conduit diameter 242 of evaporatorconduit 232. In this manner, evaporator conduit 232 may be pressed intorecessed passages 230 such that it is fully received within recessedpassages and does not protrude from or is otherwise flush with flat side220. Moreover, according to exemplary embodiments, the depth of recessedpassages 230 may be variable depending on the proximity of recessedpassages 230 to mold cavity 210. In this regard, for example, the depthof recessed passages 230 may be varied such that a distance betweenrecessed passages 230 and mold cavity 210 is relatively constant. Forexample, as illustrated, the corners where sides 220 meet may define acurved passage with variable depth so that the evaporator conduit 232may remain close to mold cavities 210 while also preventing kinking ofevaporator conduit 232.

According to exemplary embodiments of the present subject matter,evaporator conduit 232 may be pressed into recessed passages 230 forincreased thermal communication and heat conductivity therebetween. Inthis regard, for example, evaporator conduit 232 may initially bepositioned within recessed passages 230, but there may be a slightairgap between evaporator conduit 230 and ice mold 200 at one or morelocations. Therefore, evaporator conduit 230 may be further pressed intorecessed passages 230 for improved contact and more efficient heattransfer. According to still other embodiments, this pressing processmay result in a slight deformation of evaporator conduit 232, e.g., suchthat complete and continuous thermal contact is achieved betweenevaporator conduit 232 and ice mold.

In addition, the plurality of recessed passages may define a passagewidth 244 that is substantially equivalent to conduit diameter 242. Inaddition, the bottom of recessed passages 230 may be curved at the sameradius as evaporator conduit 232 for improved thermal engagement betweenevaporator conduit 232 and ice mold 200. Other variations andmodifications to the size and geometry of recessed passages 230 andevaporator conduit 232 may be used while remaining within the scope ofthe present subject matter. According still other embodiments, athermally insulating cover or topping material may be positioned overevaporator conduit 232 after it is positioned within recessed passages232, e.g., to improve the thermal coupling between evaporator assembly202 and ice mold 200.

According to exemplary embodiments, evaporator assembly 202 may includea dedicated evaporator conduit for each portion of ice mold 200.Moreover, these portions may be connected in parallel such that eachportion of ice mold 200 may receive substantially equal coolingcapacity. Specifically, according to the illustrated embodiment,evaporator assembly 202 includes a first evaporator portion 250 that ismounted within first portion 212 and a second evaporator portion 252that is mounted within second portion 214. It should be appreciated thatany other suitable plumbing configuration of evaporator conduit 232 maybe used while remaining within the scope of the present subject matter.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. An ice making assembly comprising: an ice molddefining a mold cavity, wherein the ice mold defines a plurality ofrecessed passages that at least partially surround the mold cavity; asealed refrigeration system comprising a condenser and an evaporator inserial flow communication with each other, the evaporator beingpositioned within the plurality of recessed passages to cool the icemold; and a pump assembly for urging an ice-building spray into the icemold to form an ice billet.
 2. The ice making assembly of claim 1,wherein the ice mold comprises a first portion and a second portion, thesecond portion being separable from the first portion.
 3. The ice makingassembly of claim 2, wherein the evaporator includes a first evaporatorportion mounted within the first portion and a second evaporator portionmounted within the second portion, the first evaporator portion and thesecond evaporator portion being connected in parallel.
 4. The ice makingassembly of claim 2, wherein the first portion is a mirror image of thesecond portion.
 5. The ice making assembly of claim 1, wherein the icemold is substantially rectangular having six sides, and wherein theplurality of recessed passages is formed in at least four of the sixsides of the ice mold.
 6. The ice making assembly of claim 1, whereinthe plurality of recessed passages defines a serpentine or zig-zagpattern through at least a portion of the ice mold.
 7. The ice makingassembly of claim 1, wherein the plurality of recessed passages definesan average depth that is greater than or equal to a conduit diameter ofthe evaporator.
 8. The ice making assembly of claim 1, wherein a depthof the plurality of recessed passages is variable.
 9. The ice makingassembly of claim 1, wherein the plurality of recessed passages definesan average passage width that is substantially equivalent to a conduitdiameter of the evaporator.
 10. The ice making assembly of claim 1,wherein the evaporator comprises copper tubing.
 11. The ice makingassembly of claim 1, wherein the ice mold is formed from aluminum. 12.The ice making assembly of claim 1, wherein the ice mold defines aplurality of mold cavities.
 13. The ice making assembly of claim 12,wherein a seam that divides a first portion and a second portion of theice mold passes through each of the plurality of mold cavities.
 14. Theice making assembly of claim 1, wherein the ice mold comprises more thantwo separable pieces.
 15. A mold assembly for an ice making assembly,the mold assembly comprising: an ice mold comprising a first portion anda second portion that are separable and define a mold cavity, whereinthe ice mold defines a plurality of recessed passages that at leastpartially surround the mold cavity and are configured for receivingevaporator conduit.
 16. The mold assembly of claim 15, wherein theevaporator conduit includes a first evaporator portion mounted withinthe first portion and a second evaporator portion mounted within thesecond portion, the first evaporator portion and the second evaporatorportion being connected in parallel.
 17. The mold assembly of claim 15,wherein the plurality of recessed passages defines an average depth thatis greater than or equal to a conduit diameter of the evaporatorconduit.
 18. The mold assembly of claim 15, wherein a depth of theplurality of recessed passages is variable.
 19. The mold assembly ofclaim 15, wherein the plurality of recessed passages defines an averagepassage width that is substantially equivalent to a conduit diameter ofthe evaporator conduit.
 20. The mold assembly of claim 15, wherein theevaporator conduit comprises copper tubing and the ice mold is formedfrom aluminum.